DIY freestanding cabinet

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27th November 2009

With yet another decor change and also that this tank is to be moved to the left side of the chimney breast it meant time for more cabinet work. The alcove this side is slightly smaller and rather than trim the previous cabinet to fit the space I decided I would make a freestanding one. It will be veneered in ash to match the bookcase which will be going where the tank used to be on the right of the chimney breast.

Unfortunately I didn't take pictures of the whole build process and therefore the pictures here start after I have built the frame. The actual build of this cabinet will be aesthetically poor but the viewable outer will look superb. Also some of the pictures may look like it is a mess at stages because I was using the frame as a workbench while I was working on it. A sign of just how sturdy this frame is already at this stage.

Just to run through this build. I am using 37 x 37 rough sawn wood to build the initial frame which I then panelled with 3mm mdf and then glued the veneer on top of the panels.

Stage 1 was to build a frame to become the top support. This has the same dimensions as the footprint of the tank and I am planning to put the tank straight on top of it. There will be no top as the tank already sits on top of its original OEM cabinet's top. For all frame fixings I am using decking screws as they are strong and self tap very easily. They will be hidden by the veneer when the unit is complete.

Stage 2 was to screw on the legs for the unit.

Stage 3 was to screw more 37x37 in position for the bottom shelf.

Stage 4 was to screw an upright to the front where the doors will meet and then fit a diagonal bar at the back to makes sure the unit stays in shape. These 2 are structurally very important. The diagonal most important as it stops the top and bottom pieces moving sideways under the 100+kg which will sit on top.

Stage 5 - We now have the basic frame put together and standing on top myself it doesn't move nor wobble much. Now I cut a bottom shelf to fit onto the bottom frame and then a higher shelf which is supported by shelf brackets. I used some of the previous cabinet to make these parts. A panel is fitted at the back of the lower shelf to stop things sliding out of the back of the unit. This unit will have no back so it is pretty easy getting all equipment leads and hoses out without having to thread things through holes.

At this point I left the project for a few weeks however I screwed some chipboard panels to the sides and put the tank on it. I returned a month later to finish the job off and the unit hadn't moved at all. This is the stage we are at on the first picture.

Stage 6 was to cut the mdf panels to the dimensions of the outer sides and the inside of the legs. The chipboard panels were removed and then the mdf panels fixed onto the frame using panel pins and at this point I could pull the frame a little to ensure that everything was square at least at the sides before nailing the panels into position.

With the unit now taking shape I cut some chipboard panels which cover the front. Easier to veneer onto a smooth surface than try to glue to the rough sawn wood. The second picture shows a panel being fixed to the side. The front chipboard panels already screw into position.

Stage 7. With the unit now structurally finished the hard work began of veneering it. Firstly the sides were done. This takes 3 pieces of veneer which is about 7 inches wide. each one trimmed to a straight line, glued and then weighed down individually, then the next one taped to the first along the join, glued flush and weighed down and so on until you have all the pieces glued and in position. The glue needs 24 hours to set and you can't see if has been succesful until then as the veneer will warp slightly with the moisture of the glue and then when it dries it will return to its former shape. Sometimes you look and think it is wrinkled only to find that the next day when it has dried it is perfectly flat. The third picture show one side of the unit which is now veneered.

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